Patent application title: MOTOR

Abstract:

A stator of a motor includes a stator core formed of a plurality of teeth
and an annular yoke connecting the teeth to each other, and windings
wound on the teeth. A rotor of the motor confronts the stator while
supported rotatably, and includes a rotor magnet, a rotor core, and a
position sensing magnet. The motor further includes a position sensor for
sensing a rotational position of the rotor and a circuit board for
supplying an electric current to the windings in response to the
rotational position of the rotor. The rotor magnet, the rotor core, and
the position sensing magnet are integrated into one unit, which is
mounted on a shaft of the rotor.

Claims:

1. A motor comprising:a stator including a stator core formed of a
plurality of teeth and an annular yoke coupling the teeth to each other,
and a winding provided to the teeth;a rotor confronting the stator while
rotatably supported, and including a rotor magnet, a rotor core and a
position sensing magnet;a position sensor for sensing a rotational
position of the rotor; anda circuit board for supplying an electric
current to the winding in response to the rotational position of the
rotor,wherein the rotor magnet, the rotor core and the position sensing
magnet are integrated into one unit, which is mounted on a shaft of the
rotor.

2. The motor of claim 1, wherein the position sensing magnet is axially
magnetized.

3. The motor of claim 1, wherein the position sensing magnet has a smaller
outer diameter than an outer diameter of the rotor magnet.

4. The motor of claim 1, wherein the position sensing magnet protrudes
from the rotor core along an axial direction from the rotor core toward
the position sensor.

5. The motor of claim 1, wherein along an axial direction from the rotor
core toward the position sensor, the position sensing magnet has an axial
end face being flush with or lower than an axial end face of the rotor
magnet.

6. The motor of claim 1, wherein the rotor core shapes like a cup.

7. The motor of claim 6, wherein the position sensing magnet is disposed
on an inner wall of the rotor core.

Description:

[0001]This application is a U.S. National Phase Application of PCT
International Application PCT/JP2006/324041.

TECHNICAL FIELD

[0002]The present invention relates to a motor structure accurately
sensing a rotational position of a rotor of the motor.

BACKGROUND ART

[0003]FIG. 5 shows a motor structure of prior art 1, and this motor is
formed of stator 40 and rotor 50. Stator 40 comprises the following
elements: stator core 41, winding 43 wound via insulator 42 on respective
teeth of stator core 41 in a concentrated manner, terminal 44, circuit
board 45, resin mold 46 for sealing all or parts of the elements
discussed above, and bracket 47. Three-phase windings are regularly used
in this motor. Circuit board 45 includes various components necessary for
driving the motor.

[0004]Rotor 50 is placed inside of stator 40, and has shaft 53 at the
center of rotor core 52. Shaft 53 is rotatably supported by two bearings
54. Rotor 50 forms a surface magnet rotor, i.e. rotor magnet 51 is
mounted on an outer wall of rotor core 52. Rotor 50 rotates on shaft 53
due to the interaction between the magnetic field formed by an electric
current running through winding 43 wound on stator 40 and the magnetic
poles of rotor magnet 51.

[0005]Driving of the motor needs to regulate the electric current running
through winding 43 in response to a rotational position of rotor 50, so
that some means is needed for accurately sensing the rotational position
of rotor 50.

[0006]In a conventional manner, position sensor 61, such as a Hall element
or a Hall IC, mounted to circuit board 45 is used in many cases as a
means for sensing the rotational position for the motor to sense the
rotational position of rotor 50.

[0007]At this time, extra-close placement of rotor magnet 51 mounted on
rotor 50 to position sensor 61 allows sensing a major magnetic flux,
which rotates rotor 50, generated from rotor magnet 51. However, in
actual, presence of a coil end, namely, a protruding part of winding 43
from stator core 41, sets a limit to the closer placement of rotor magnet
51 to position sensor 61. The extra-close placement of rotor magnet 51 to
position sensor 61 also refers to the close placement of position sensor
61 to stator core 41 or winding 43. As a result, position sensor 61 is
affected by the magnetic flux, which is generated by the electric current
running through winding 43 and issued from stator 40, so that the
accuracy of sensing the rotor position is lowered, for position sensor 61
originally aims to sense the rotor position by sensing the magnetic flux
issued from rotor magnet 51.

[0008]FIG. 6 shows a motor structure of prior art 2. Elements similar to
those of prior art 1 shown in FIG. 5 have the same reference marks, and
the descriptions thereof are omitted here. The motor of prior art 2
differs from the motor of prior art 1 in the following point: As shown in
FIG. 6, position sensing magnet 62 is mounted to rotor 50 besides rotor
magnet 51. Position sensing magnet 62 is axially magnetized so that the
magnetic flux generated from magnet 62 can positively interlink with
position sensor 61, which thus accurately senses a rotational position of
rotor 50. This structure is disclosed in, e.g. Unexamined Japanese Patent
Publication No. H11-299207.

[0009]The motor of prior art 2, however, has discrete components of rotor
magnet 51 and position sensing magnet 62, so that variations are obliged
to happen in the positional relation between magnet 51 and magnet 62 both
mounted to rotor core 52. The variations sometimes lower the accuracy of
sensing the position, and the structure discussed above increases the
number of steps of assembling rotor 50.

DISCLOSURE OF INVENTION

[0010]A motor of the present invention includes a stator and a rotor. The
stator is formed of a stator core comprising a plurality of teeth and an
annular yoke for coupling the teeth to each other, and windings provided
to the teeth. The rotor is rotatably supported while confronting the
stator, and is formed of a rotor magnet, a rotor core and a position
sensing magnet. The motor of the present invention further includes a
position sensor for sensing a rotational position of the rotor, and a
circuit board for supplying an electric current to the windings in
response to the rotational position of the rotor. The rotor magnet, the
rotor core, and the position sensing magnet are integrated into one unit,
which is mounted to a shaft of the rotor.

[0011]The foregoing structure allows eliminating assembly variations
occurring when the rotor core is mounted to the shaft, so that the
accuracy of sensing the rotor position can be improved. As a result, a
reliable motor can be available.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 shows a structure of a motor in accordance with a first
embodiment of the present invention.

[0013]FIG. 2 shows a structure of a motor in accordance with a second
embodiment of the present invention.

[0014]FIG. 3 shows a structure of a motor in accordance with a third
embodiment of the present invention.

[0015]FIG. 4 shows a structure of a motor in accordance with a fourth
embodiment of the present invention.

[0018]Exemplary embodiments of the present invention are demonstrated
hereinafter with reference to the accompanying drawings.

Embodiment 1

[0019]FIG. 1 shows a structure of a motor in accordance with the first
embodiment of the present invention. In FIG. 1, the left half, defined
with the center line drawn in an alternate long and short dash line,
shows a sectional view of the motor. First, major structural elements of
the motor are described with reference to FIG. 1.

[0020]The motor in accordance with this first embodiment of the present
invention includes stator 10 and rotor 30. Stator 10 is formed of stator
core 11 comprising a plurality of teeth (not shown) and an annular yoke
for coupling the teeth to each other, and windings 13 provided to the
teeth. Rotor 30 is rotatably supported while it confronts stator 10, and
is formed of rotor magnet 31, rotor core 32, and position sensing magnet
33. The motor of the present invention further includes position sensor
21 for sensing a rotational position of rotor 30, and circuit board 15
for supplying an electric current to the windings in response to the
rotational position of rotor 30. Rotor magnet 31, rotor core 32, and
position sensing magnet 33 are integrated into one unit, which is then
mounted to shaft 34 of rotor 30.

[0021]The structure of the motor in accordance with this first embodiment
is detailed hereinafter. The motor shown in FIG. 1 is a brushless motor
of which respective teeth of stator core 11 are wound with concentrated
windings 13, and includes stator 10 and rotor 30.

[0022]Stator 10 comprises the following elements: [0023]stator core 11;
[0024]winding 13 wound on, via insulator 12, respective teeth of stator
core 11; [0025]circuit board 15; [0026]terminal 14 for electrically
coupling an end of winding 13 to circuit board 15; [0027]resin mold 16
for sealing all or parts of the foregoing elements with resin; and
[0028]bracket 17.Each one of the teeth is wound with a three-phase
winding. In this winding, an electric current having a phase difference
of 120 degrees in electrical angles from each other runs. Circuit board
15 includes position sensor 21 and other components necessary for driving
the motor.

[0029]Rotor 30 is placed inside of stator 10 such that it confronts stator
10 via a clearance. Rotor 30 includes shaft 34 at the center of rotor
core 32. Shaft 34 is rotatably supported by two bearings 35. First
bearing 35 is held by resin mold 16, and second bearing 35 is held by
bracket 17. Rotor 30 forms a surface magnet rotor, i.e. rotor magnet 31
is mounted on the outer wall of rotor core 32. Rotor magnet 31, rotor
core 32 and position sensing magnet 33 are integrated into one unit,
which is then mounted on shaft 34.

[0030]Rotor 30 rotates on shaft 34 due to interaction between the magnetic
field generated by the electric current running through winding 13 of
stator 10 and the magnetic poles of rotor magnet 31. At this time,
position sensor 21 senses a position of rotor 30, and the electric
current running through winding 13 is regulated in response to the
rotational position of rotor 30.

[0031]In general, if rotor magnet 31 has some positional deviation along
the rotating direction from the magnetic poles of position sensing magnet
33, the three-phase current running through winding 13 is disturbed. As a
result, torque ripple occurs, which causes degradation the motor
characteristics such as increment of vibrations and noises accompanying
the motor rotation or decrement of the torque constant. The decrement of
torque constant invites temperature rise in the motor, so that the
reliability of the motor lowers.

[0032]However, in the structure described in this embodiment, i.e. rotor
magnet 31, rotor core 32, and position sensing magnet 33 are integrated
into one unit, which is then mounted on shaft 34, no positional deviation
can be expected between rotor magnet 31 and position sensing magnet 33
along the rotating direction during the assembly of rotor 30. This
structure thus allows eliminating variations during the assembly of rotor
30, and improving the accuracy of sensing the rotor position. As a
result, not only an improvement in the characteristics but also an
improvement in the reliability of the motor can be expected.

[0033]In addition to the foregoing structure, axial magnetizing of
position sensing magnet 33 will increase the magnetic flux interlinking
with position sensor 21 out of the entire magnetic flux generated from
position sensing magnet 33. In other words, interlinking flux can be
increased, which assures sensing the rotational position of rotor 30, so
that the motor reliability can be further improved.

[0034]It is necessary to take it into consideration that another magnetic
flux generated from stator 10 also interlinks with position sensor 21
besides the magnetic flux generated by position sensing magnet 33. This
another magnetic flux has a different phase from that of the magnetic
flux generated by magnet 33, and affects sensor 21 in different magnitude
depending on the amount of the electric current running through winding
13. As a result, the difference between a rotational position sensed by
sensor 21 and an actual rotational position of rotor 30 varies depending
on the torque generated by the motor. This refers to that some variations
occur in the accuracy of sensing the position, and this is an undesirable
matter with respect to the motor characteristics as well as the motor
reliability.

[0035]The first embodiment addresses the foregoing problems, and employs
position sensing magnet 33 having a smaller outer diameter than that of
rotor magnet 31. This structure allows reducing the influence caused by
the magnetic flux generated from stator 10. Rotor 30, in general, is
required to be placed near stator core 11 or winding 13 along the radial
direction because it generates the magnetic flux necessary for rotating
rotor 30. In this connection, the outer diameter of position sensing
magnet 33 is set as small as possible comparing with that of rotor magnet
31, so that the distance along the radial direction between magnet 33 and
stator core 11 or winding 13 becomes greater. The magnetic flux generated
by magnet 33 is thus less affected by the magnetic flux generated from
stator 10. On top of this preparation, as shown in FIG. 1, position
sensor 21 is placed on circuit board 15 along the radial direction such
that sensor 21 axially confronts position sensing magnet 33. This
structure is preferable because the magnetic flux generated from stator
10 hardly interlinks with position sensor 21.

[0036]Circuit board 15 can have a ferromagnetic substance axially on its
opposite face to rotor 30, or circuit board 15 per se can be formed of
ferromagnetic material so that the magnetic flux generated by position
sensing magnet 33 can positively interlink with position sensor 21.

Embodiment 2

[0037]FIG. 2 shows a structure of a motor in accordance with the second
embodiment of the present invention. In FIG. 2, similar elements to those
in the first embodiment shown in FIG. 1 have the same reference marks,
and the descriptions thereof are omitted here. The motor in accordance
with the second embodiment differs from that of the first embodiment
shown in FIG. 1 in the following point: As shown in FIG. 2, the motor in
accordance with the second embodiment has position sensing magnet 33
protruding axially from rotor core 32 toward position sensor 21. This
structure allows reducing the magnetic flux interlinking with rotor core
32 out of the entire magnetic flux generated from position sensing magnet
33 while increasing the magnetic flux interlinking with position sensor
21. As a result, position sensor 21 can accurately sense a rotational
position of rotor 30.

Embodiment 3

[0038]FIG. 3 shows a structure of a motor in accordance with the third
embodiment of the present invention. In FIG. 3, similar elements to those
of the first embodiment shown in FIG. 1 and those of the second
embodiment shown in FIG. 2 have the same reference marks, and the
descriptions thereof are omitted here.

[0039]As shown in FIG. 3, the motor in accordance with the third
embodiment has position sensing magnet 33 integrated with rotor core 32
into one unit; however, magnet 33 is not needed to protrude from the
axial end face of rotor magnet 31. In other words, along the axial
direction from rotor core 32 toward position sensor 21, an axial end face
of magnet 33 can be flush with or lower than the axial end face of rotor
magnet 31.

[0040]This structure allows the magnetic flux generated by magnet 33 to be
less affected by the magnetic flux generated from stator 10. As a result,
position sensor 21 can accurately sense a rotational position of rotor
30.

Embodiment 4

[0041]FIG. 4 shows a structure of a motor in accordance with the fourth
embodiment of the present invention. In FIG. 4, similar elements to those
of embodiments 1, 2 and 3 respectively shown in FIGS. 1, 2 and 3 have the
same reference marks, and the descriptions thereof are omitted here.

[0042]As shown in FIG. 4, the motor in accordance with the fourth
embodiment has rotor core 32 shaping like a cup, and position sensing
magnet 33 is placed on an inner wall of cup-like rotor core 32.

[0043]Since rotor core 32 shapes like a cup, it only needs the minimum
amount of material necessary for rotor magnet 31 and position sensing
magnet 33, so that the cost of the motor can be reduced. Use of rotor
magnet 31 having weak magnetic force or anisotropic poles, in particular,
will save rotor core 32 a greater size in radius direction, so that the
foregoing structure is preferable for constructing a magnetic circuit.

[0044]The placement of position sensing magnet 33 on the inner wall of
cup-like rotor core 32 increases a space between magnet 33 and stator
core 11 or winding 13 in the radius direction, so that the magnetic flux
generated by magnet 33 is hardly affected by the magnetic flux generated
from stator 10. Out of the entire magnetic flux generated by rotor magnet
31, leakage flux, which leaks and does not interlink with stator core 11,
interlinks with rotor core 32, so that the entire magnetic flux less
affects position sensing magnet 33. As a result, the accuracy of sensing
the rotor position can be improved.

[0045]In the embodiments discussed previously, the brushless motor
employing the concentrated winding on the stator teeth is used; however,
the present invention can be applied not only to brushless motors
employing a distributed winding on the stator teeth, but also to a
variety of motors which need sensing their rotors' rotational positions.

INDUSTRIAL APPLICABILITY

[0046]The present invention allows a motor to sense its rotor's rotational
position for driving the motor. The motor is thus useful for an
application requiring reliability, and an application that needs reducing
the characteristics degradation invited by lowering the sensing accuracy
of the rotor position, or an application that needs lowering vibrations
and noises as much as possible.